Methods of making metal-doped nickel oxide active materials

Abstract

Methods of making high-energy cathode active materials for primary alkaline batteries are described. The primary batteries include a cathode having an alkali-deficient nickel(IV)-containing oxide including one or more metals such as Co, Mg, Al, Ca, Y, Mn, and/or non-metals such as B, Si, Ge or a combination of metal and/or non-metal atoms as dopants partially substituted for Ni and/or Li in the crystal lattice; an anode; a separator between the cathode and the anode; and an alkaline electrolyte solution.

What is claimed is: 
     
       1. A method of making a battery, comprising incorporating a cathode including as the cathode active material a lithium-deficient doped nickel(IV)-containing oxide having a formula A x Ni 1-y-z-w Co y M a   z M b   w O 2  wherein A comprises lithium, M a  is selected from the group consisting of Ca, Mg, Al, Y, Mn, and any combination thereof; and M b  is selected from the group consisting of B, Si, Ge, and any combination thereof; 0≦x≦0.08; 0≦w≦0.02; and 0.02≦y+z≦0.25 prepared by acid treatment of a LiNi 1-y-z-w , Co y M a   z M b   w O 2  precursor having a layered or spinel-type crystal structure into the battery wherein 0≦w≦0.02; 0≦y≦0.02; 0.02≦z≦0.08; M a  is selected from the group consisting of Ca, Mg, Al, Y, Mn, and any combination thereof; and M b  is selected from the group consisting of B, Si, Ge, and any combination thereof. 
     
     
       2. The method of  claim 1 , further comprising incorporating an anode including zinc or zinc alloy particles, an alkaline electrolyte solution, and a separator into the battery. 
     
     
       3. The method of  claim 1 , wherein the cathode further includes an oxidation-resistant, electrically-conductive carbon additive. 
     
     
       4. The method of  claim 1 , wherein the oxidation-resistant, electrically-conductive carbon additive is selected from synthetic, non-expanded oxidation-resistant graphite, graphitized carbon black, vapor phase grown carbon fibers, and carbon nanofibers. 
     
     
       5. The method of  claim 1 , wherein the carbon additive is included in the cathode at a level of between 3% and 20% of the total cathode weight. 
     
     
       6. The method of  claim 1 , wherein the carbon additive is included in the cathode at a level of between 3% and 10% of the total cathode weight.